Face mask with adjustable earloops

ABSTRACT

A method and apparatus for forming a face mask having a panel with a pair of adjustable earloops. The panel may comprise one, two, three or more layers. Preferably, but not necessarily, the panel may comprise a inner fibrous filtering material with microscopic openings that is sandwiched between two outer layers. The fibrous filtering material may filter contaminates while the two outer layers protect the fibrous filtering material and may also provide some filtering. The two outer layers may be formed from a polymer based fabric such that the edges of the two outer layers may be thermally bonded.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND

1. The Field of the Present Disclosure

The present disclosure relates generally to face masks, and more particularly, but not necessarily entirely, to face masks with earloops.

2. Description of Related Art

A wide range of protective face masks are available on the market to accommodate various situations. Typically, most face masks comprise a panel dimensioned to cover a wearer's mouth and nostrils. The panel may serve as a filter to prevent undesirable contaminants and pathogens from being inhaled by the wearer. In this regard, the panel may comprise a fibrous filtering material with microscopic openings that is sandwiched between two air-permeable outer layers. The fibrous filtering material may filter contaminates while the two outer layers protect the fibrous filtering material. The two outer layers may be formed from a polymer-based fabric.

Various means are known to hold the panel in place over the user's mouth and nostrils. Most commonly, the panel is held in place with tie straps or earloops. For example, U.S. Pat. No. 4,941,470, granted Jul. 17, 1990 to Hubbard et al., discloses a face mask having a fabric panel held in place by a pair of earloops. The earloops are fabricated from a layer of elastically deformable heat malleable material. Each of the earloops are attached to the fabric panel on one side thereof with a heat formed seal. That is, the earloops and the fabric panel are bonded together by applying heat to the juncture of the free ends of the earloops and the fabric panel.

One drawback to the face mask of the '470 patent is that, other than the natural elasticity of the earloops, the length of the earloops are non-adjustable. This is problematic because the elasticity of the earloops does not adequately accommodate for the large disparity in the physical features of the wearers. That is, the earloops are manufactured as a one-size fits all, but the position of the ears on a head and the width and size of the nose varies between people in general, including between genders and between different ethnic groups.

Increasingly, wearers of face masks of the type disclosed in the '470 patent are becoming dissatisfied with the one size fits all approach. In particular, some wearers of face masks of the type disclosed in the '470 patent have complained that the earloops are too tight. Given that a typical wearer in a health care setting may don multiple masks in one day, tight earloops may cause discomfort, including headaches and ear pain. In some instances, wearers may unwisely choose not to wear the face masks because of the discomfort caused by the earloops. It would therefore be an improvement over the prior art to provide low-cost, disposable face masks with adjustable earloops that is easy to manufacture.

The prior art is thus characterized by several disadvantages that are addressed by the present disclosure. The present disclosure minimizes, and in some aspects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein.

The features and advantages of the present disclosure will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the present disclosure without undue experimentation. The features and advantages of the present disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the disclosure will become apparent from a consideration of the subsequent detailed description presented in connection with the accompanying drawings in which:

FIG. 1 depicts a front view of a face mask according to an embodiment of the present disclosure;

FIG. 2 depicts a rear view of the face mask shown in FIG. 1;

FIG. 3 depicts a front view of a face mask according to an embodiment of the present disclosure;

FIG. 4 depicts a front view of a face mask according to an embodiment of the present disclosure;

FIG. 5 depicts a front view of a face mask according to an embodiment of the present disclosure;

FIG. 6 depicts a front view of a face mask according to an embodiment of the present disclosure;

FIG. 7 depicts a front view of a face mask according to an embodiment of the present disclosure;

FIG. 8 depicts a front view of a face mask according to an embodiment of the present disclosure; and

FIG. 9 depicts a front view of a face mask according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles in accordance with the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the disclosure as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the disclosure claimed.

In describing and claiming the present disclosure, the following terminology will be used in accordance with the definitions set out below. As used herein, the terms “comprising,” “including,” “containing,” “having,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps. It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

In an embodiment, the present invention comprises a method and apparatus for forming a face mask having a panel with a pair of adjustable earloops. The panel may comprise one, two, three or more layers. Preferably, but not necessarily, the panel may comprise an inner fibrous filtering material with microscopic openings that is sandwiched between two outer layers. The fibrous filtering material may filter contaminates while the two outer layers protect the fibrous filtering material and may also provide some filtering. The two outer layers may be formed from a polymer based fabric such that the edges of the two outer layers may be thermally bonded.

According to another aspect of the invention, each of the earloops may be formed from an elongated member. Each of the elongated members may comprise a first end and a second end. The first end and second end of each of the elongated members may be tacked to the panel, by heat bonding or in some other manner, such as stitching. In addition, according to another aspect of the invention, an intermediate portion of each of the elongated members may be threaded through a hole in the panel to form the earloop and a take-up loop. In this regard, each earloop may extend from the tacked first end of an elongated member to the hole in the panel and the take-up loop of the same elongated member may extend from the hole in the panel to the tacked second end.

According to another aspect of the invention, the earloops may be placed around a wearer's ears while the take-up loops may provide adjustability to increase or decrease the size of the earloops. In particular, the size of the take-up loops may be wearer adjustable to vary the size of their respective earloops. According to another aspect of the invention, the holes for the elongated members may be located in a heat bonded portion of the panels and may be slightly smaller than the diameters of the elongated members to provide a clamping, holding or compressing force on the elongated members.

Referring now to FIGS. 1 and 2, there is depicted a face mask 100 according to an embodiment of the present disclosure. The face mask 100 may comprise a panel 102. In an embodiment, the panel 102 may be substantially rectangular in shape and comprise a horizontal top edge 104, a horizontal bottom edge 106, a left vertical edge 108 and a right vertical edge 110. In an embodiment, a plurality of pleats 112 may extend horizontally with respect to the face of a wearer. It will be appreciated that the pleats 112 may expand when the face mask 100 is put on by a wearer. The pleats 112 may be formed by folding the panel 102 and tacking the ends of the pleats 112 by heat bonding or in some other manner, such as stitching.

In an embodiment, the panel 102 may comprise a plurality of layers. For example, the panel 102 may comprise a fibrous filtering material with microscopic openings that is sandwiched between two air-permeable outer layers. The inner fibrous filtering material may filter contaminates while the two outer layers protect the fibrous filtering material. The two outer layers may be formed from a fabric formed from a thermoplastic polymer. In particular, the two outer layers may be formed by melt blowing. (Melt blowing is a one-step process in which high-velocity air blows a molten thermoplastic resin from an extruder die tip onto a conveyor or takeup screen to form a fine fiberous and self-bonding web.) It will be appreciated that the panel 102 may comprise one, two, three, four, five or more layers. In an embodiment, the layers of the panel 102 may comprise a non-woven synthetic material. In an embodiment, one or more layers of the panel 102 may be formed from a woven material, such as cotton or the like. In an embodiment, the face mask 100 may be a one-time use mask or a reusable mask. For example, the face mask 100 may be washable.

In an embodiment, the layers of the panel 102 may be joined using a heat bonding process. As known to those of ordinary skill, heat bonding involves applying heat and pressure to the layers of the panel 102. The portion of the layers subjected to the heat and pressure may then melt together. In particular, as shown in FIG. 1, heat bonds 114 may be formed along a perimeter of the panel 102 to join the various layers together and to form the pleats 112.

In an embodiment, elongated members 120 be attached adjacent the left vertical edge 108 and the right vertical edge 110, respectively. Each of the elongated members 120 may have a first end 122 and a second end 124. The first end 122 and the second end 124 of each of the elongated members 120 may each be tacked to the panel 102. In an embodiment, the first end 122 and the second end 124 of each of the elongated members 120 may be joined to the panel 102 by heat bonding. In an embodiment, the first end 122 and the second end 124 of each of the elongated members 120 may be joined to the panel 102 by an adhesive. In an embodiment, the first end 122 and the second end 124 of each of the elongated members 120 may be joined to the panel 102 by stitching. It will be appreciated that the first end 122 and the second end 124 of each of the elongated members 120 may be joined to the panel 102 in any manner known to those having ordinary skill in the art.

In an embodiment, the panel 102 may comprise holes 126 for receiving an intermediate portion of the elongated members 120. It will be appreciated that holes 126 may be located anywhere on the panel 102, including in the top or bottom corners. That is, each of the elongated members 120 may pass through one of the holes 126. It will be appreciated that the holes 126 may be formed in a heat bonded portion of the panel 102. That is, a perimeter of the holes 126 may be heat bonded. It will be appreciated that the elongated members 120 may pass from front-to-back or back-to-front according to embodiments of the present invention.

In an embodiment, an intermediate portion of each of the elongated members 120 may be threaded through one of the holes 126 in the panel 102 such that the elongated members 120 each define an earloop 130 and a take-up loop 132. In this regard, each earlooop 130 may extend from the first end 122 of its elongated member 126 to one of the hole 126 and the take-up loop 132 may extend from the hole 126 to the second end 124 of the elongated member.

In an embodiment, the elongated members 120 may be deformable when placed under tension. In this regard, a diameter of each of the elongated members 120 narrows when the elongated members 120 are placed under tension. In an embodiment, the elongated members 120 may be elastically deformable. The elongated members 120 may be formed of a polymer.

It will be appreciated that the size of the earloops 130 may be adjustable to accommodate wearers of different sizes by varying the size of the take-up loops 132. A wearer may decrease the size of the earloops 130 by increasing the size of the take-up loops 132. A wearer may increase the size of the earloops 130 by decreasing the size of the take-up loops 132.

The sidewalls of the holes 126 in the panel 102 may be configured and dimensioned to apply a compressive force on the elongated members 120. In particular, because the holes 126 may be formed in a heat bonded portion of the panel 102, the heat bonded portion provides rigidity and reinforcement to the sidewalls of the holes 126 sufficient to provide a compressive force on the elongated members 120. Without the reinforcement provided by the heat bonded portion of the panel 102, the one or more layers forming the panel 102 would not have sufficient rigidity to provide a compressive force on the elongated members 120. A wearer may overcome the compressive force applied by the sidewalls of the holes 126 when adjusting the size of the earloops 130 by tensioning the elongated members 120, which decreases the diameter of the elongated members 120. When not under tension, the compressive force provided by the sidewalls of the holes 126 maintains the current position of the elongated members 120.

In an embodiment, the face mask 100 may be constructed by stacking the layers that form the panel 102. Then, at least one heated element may be pressed against an outer one of the layers, which causes the layers to “melt” together in the locations shown in FIG. 1 to form a heat bond. Holes 126 may then be formed through the panel 102 by a punch, needle, cutter, or in some other manner. Each elongated member 120 may be threaded through one of the holes and the ends 122 and 124 of the elongated members 120 may be heat bonded by a heating element or otherwise tacked to the panel 120. In an embodiment of the present disclosure, the second ends 124 of the elongated members 120 may be free or not tacked to the panel 102. In short, using essentially the same materials and construction techniques as the prior art face masks, the present invention provides a low-cost, disposable face mask with adjustable earloops as shown in FIG. 1.

Referring now to FIG. 3, there is shown a face mask 200 having a panel 202 similar to the panel 102 shown and described above in relation to FIGS. 1 and 2. Attached to the panel 202 may be elongated members 204. A first end 206 of each of the elongated members 204 may be tacked to the panel 202 by heat bonding, stitching or in some other manner. A second end 208 of each of the elongated members 204 may be free, i.e, unattached to the panel 202. An intermediate portion of each of the elongated members 204 may extend through a pull through tab 210. In an embodiment, the pull through tab 210 may be formed of plastic or a heat bonded polymer based fabric. The pull through tab 210 may impose a compressive force on the elongated members 204 to hold them in position. Each of the elongated members 204 may define an earloop 212 that extends from its first end 206 to the tab 210.

Referring now to FIG. 4, there is shown a face mask 300 having a panel 302 similar to the panel 102 shown and described above in relation to FIGS. 1 and 2. Attached to the panel 302 may be elongated members 304. A first end 306 of each of the elongated members 304 may be tacked to the panel 302 by heat bonding, stitching or in some other manner. A second end 308 of each of the elongated members 304 may be free, i.e, unattached to the panel 302. An intermediate portion of each of the elongated members 304 may extend through a hole 310 in the panel 302. In an embodiment, the hole 310 may be formed in a heat bonded portion of the panel 302. The hole 310 may impose a compressive force on the elongated members 304 to hold them in position. Each of the elongated members 304 may define an earloop 312 that extends from its first end 306 to the hole 310. A wearer may pull the second ends 308 to adjust the size of the earloops 312.

Referring now to FIG. 5, there is shown a face mask 400 having a panel 402 similar to the panel 102 shown and described above in relation to FIGS. 1 and 2. Attached to the panel 402 may be elongated members 404. A first end 406 of each of the elongated members 404 may be tacked to the panel 402 by heat bonding, stitching or in some other manner. A second end 408 of each of the elongated members 404 may be free, i.e, unattached to the panel 402. An intermediate portion of each of the elongated members 404 may extend through a pair of holes 410 in the panel 402. In an embodiment, the pair of holes 410 may be formed in a heat bonded portion of the panel 402. The holes 410 may impose a compressive force on the elongated members 404 to hold them in position. Each of the elongated members 404 may define an earloop 412 that extends from its first end 406 to the pair of holes 410. A wearer may pull the second ends 408 to adjust the size of the earloops 312.

Referring now to FIG. 6, there is shown a face mask 500 having a panel 502 similar to the panel 102 shown and described above in relation to FIGS. 1 and 2. Attached to the panel 502 may be elongated members 504. A first end 506 of each of the elongated members 504 may be tacked to the panel 502 by heat bonding, stitching or in some other manner. A second end 508 of each of the elongated members 504 may be free, i.e, unattached to the panel 502. An intermediate portion of each of the elongated members 504 may extend through a pair of holes 510 in the panel 502. In an embodiment, the holes 510 may be formed in a heat bonded portion of the panel 502. The holes 510 may impose a compressive force on the elongated members 504 to hold them in position. Each of the elongated members 504 may define an earloop 512 that extends from its first end 506 to the first one of the holes 510. A wearer may pull the second ends 508 to adjust the size of the earloops 312.

Referring now to FIG. 7, there is shown a face mask 600 having a panel 602 similar to the panel 102 shown and described above in relation to FIGS. 1 and 2. Attached to the panel 602 may be elongated members 604. A first end 606 of each of the elongated members 604 may be tacked to the panel 602 by heat bonding, stitching or in some other manner. A second end 608 of each of the elongated members 604 may be free, i.e, unattached to the panel 602. An intermediate portion 609 of each of the elongated members 604 may extend through a hole 610 in the panel 602 and between the layers of the panel 602 as shown by the dashed lines. In an embodiment, the holes 610 may be formed in a heat bonded portion of the panel 602. The second ends 608 of the elongated members 604 may extend through holes 611 and may be joined together by a tab 613. Each of the elongated members 604 may define an earloop 612 that extends from its first end 606 to the holes 610.

Referring now to FIG. 8, there is shown a face mask 700 having a panel 702 similar to the panel 102 shown and described above in relation to FIGS. 1 and 2. Attached to the panel 702 may be a first set elongated members 704. A first end 706 of each of the first elongated members 704 may be tacked to the panel 702 by heat bonding, stitching or in some other manner. A second end 708 of each of the first elongated members 704 may be free, i.e, unattached to the panel 702. A second set of elongated members 705 may be attached to the panel 702. A first end 707 of the second elongated members 705 may be attached to the panel 702 and a second end 709 of the second elongated members 705 may be attached to an intermediate portion of one of the first elongated members 704 by a slider 711. One of the first elongated members 704 and one of the second elongate members 705 define an earloop 712 that is adjustable in size by varying the position of the slider 711.

Referring now to FIG. 9, there is shown a face mask 800 having a preformed panel 802. Attached to the panel 802 may be elongated members 804. A first end 806 of each of the elongated members 804 may be tacked to the panel 802 by heat bonding, stitching or in some other manner. A second end 808 of each of the elongated members 804 may be free, i.e, unattached to the panel 802. An intermediate portion of each of the elongated members 804 may extend through a hole 810 in the panel 802. The hole 810 may impose a compressive force on the elongated members 804 to hold them in position. Each of the elongated members 804 may define an earloop 812 that extends from its first end 806 to the hole 810. A wearer may pull the second ends 808 to adjust the size of the earloops 812.

Although the face masks disclosed herein may be used in any setting, they are particularly suited for use in sanitary environments by medical professionals.

According to an embodiment of the present disclosure, a face mask may comprise: a panel defined by at least one layer of fabric; the panel having a heat bonded portion; a pair of holes formed in the heat bonded portion; each of the pair of holes having a sidewall forming a hole perimeter, wherein each of the sidewalls are reinforced by the heat bonded portion of the fabric; a pair of elongated members having a first end and a second end; each of the pair of elongated members having an intermediate portion passing through one of the holes; each of the pair of elongated members having a first end and a second end; wherein the first end of each of the pair of elongated members is tacked to the panel; wherein each of the elongated members defines an earloop between its first end and the hole through which it passes. In an embodiment, the fabric is a melt blown fabric. In an embodiment, the fabric is formed from a resin. In an embodiment, the resin is a polymer resin. In an embodiment, the second end of each the elongated members is tacked to the panel, wherein each of the elongated members defines take-up loop between one of the holes and its second end. In an embodiment, the elongated members are elastically deformable. In an embodiment, each of the holes is unreinforced except by the heat bonding. In an embodiment, each of the holes imposes a compressive force on one of the elongated members. In an embodiment, the at least one layer of fabric comprises one of two and three layers of fabric. In an embodiment, the panel has a thickness no greater than 1, 2, 3, 4 or 5 millimeters. In an embodiment, the panel has a thickness less than 2 millimeters. In an embodiment, the panel has thickness less than 1.5 or 1 millimeters. In an embodiment, a thickness of the panel adjacent the holes has a thickness no greater than 1, 2, 3, 4 or 5 millimeters. In an embodiment, a thickness of the panel adjacent the holes has a thickness less than 2 millimeters. In an embodiment, in an embodiment, a thickness of the panel adjacent the holes has a thickness less than 1.5 or 1 millimeters. As used herein, the term “adjacent” means within 3 millimeters. In an embodiment, the panel comprises at least one pleat. In an embodiment, the panel is one of rectangular, triangular, circular and non-rectangular.

Those having ordinary skill in the relevant art will appreciate the advantages provide by the features of the present disclosure. For example, it is a feature of the present disclosure to provide a face mask with adjustable earloops. Another feature of the present disclosure to provide such a face mask using essentially the same materials and construction techniques as the prior art face masks. It is a further feature of the present disclosure, in accordance with one aspect thereof, to provide a face mask for medical procedures having adjustable earloops to accommodate wearers of various sizes. It is still a another feature of the present invention to provide a face mask for respiratory protection useful for use in any of the following industries: Healthcare (medical, dental, vet); Estheticians (nail, hair, etc.); Mining; Agriculture; Construction (road, paint, demolition, carpentry, etc.); Chemical Manufacturing and research; and Automotive manufacture; Pharmaceutical manufacturing and research. In addition, the face mask disclosed herein may be utilized by anyone who works with or could be exposed to bacteria, infectious diseases, dust, molds, spores, fumes, vapors, gases or other airborne particulates. It will be appreciated that face masks according to the present invention may be adapted depending on the industry and the type of exposure (gases, bacteria, dust, mold etc). For example, medical masks are typically called Procedural OR Surgical Face Masks (CDC), more protective masks are called respirators (there are many ratings and types of these, examples would be HEPA, N95, etc.). Further, different levels and types of respirators are used in the industries/occupations listed above, including medical/dental. Most healthcare workers use a procedural or surgical mask but in some cases they do opt for the additional protection offered by a respirator.

In an embodiment, a face mask according to the present invention may include a moisture indicator. In particular, it is known that prolonged use of a face mask may cause the panel to become wet with moisture from the wearer's breath. It is further known that excess moisture on the panel of a face mask provides a pathway for pathogens to enter a wearer's respiratory system. In an embodiment, the moisture indicator may include a solution-type moisture indicating ink applied to the panel. The indicator ink may include a moisture indicating substance which changes color under the influence of moisture. In an embodiment, the moisture indicator may include cobaltous chloride which changes color at a predetermined moisture level. But, it will be appreciated that any indicator that changes color at a predetermined moisture level may be used. The moisture indicator may be applied to the outer layer of the panel. In an embodiment, the moisture indicator may by embedded in a stick on dot that is applied to the panel of the face mask. It will be appreciated that the change of color of the moisture indicator may indicate to a wearer that the protection provided by the face mask has been compromised and that the wearer should replace the face mask with a new one.

In the foregoing Detailed Description, various features of the present disclosure are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description of the Disclosure by this reference, with each claim standing on its own as a separate embodiment of the present disclosure.

It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present disclosure. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present disclosure and the appended claims are intended to cover such modifications and arrangements. Thus, while the present disclosure has been shown in the drawings and described above with particularity and detail, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein. 

1-20. (canceled)
 21. A face mask comprising: a panel defined by at feast one layer of fabric; the panel having a bonded portion; a pair of holes formed is the bonded portion; each of the pair of holes having a sidewall forming a hole perimeter; a pair of elongated members; each of the pair of elongated members having an intermediate portion passing through one of the holes; each of the pair of elongated members having a first end and a second end; wherein the first end of each of the pair of elongated members is tacked to the panel; wherein each of the elongated members defines an earloop between its first end and the hole through which it passes.
 22. The face mask of claim 21, wherein the fabric is a melt blown fabric.
 23. The face mask of claim 21, wherein the fabric is formed from a resin.
 24. The face mask of claim 23, wherein the resin is a polymer resin.
 25. The face mask of claim 21, wherein the second end of each the elongated members is tacked to the panel, wherein each of the elongated members defines take-up loop between one of the holes and its second end.
 26. The face mask of claim 21, wherein the elongated members are elastically deformable.
 27. The face mask of claim 21, wherein each of the holes is unreinforced.
 28. The face mask of claim 21, wherein each of the hole sidewalls imposes a compressive force on one of the elongated members.
 29. The face mask of claim 21, wherein the at least one layer of fabric comprises one, two, three, four, or five layers of fabric.
 30. The face mask of claim 21, wherein the panel has a thickness no greater than 5 millimeters.
 31. The face mask of claim 21, wherein the panel comprises at least one pleat.
 32. The face mask of claim 21, wherein the bonded portion is a heat bonded portion.
 33. A method of fabricating a face mask, comprising: bonding a plurality of layers of fabric together to form a panel; forming a pair of holes in the panel in a bonded portion of the panel, each of the holes having a sidewall; passing a first elongated member through one of the pair of holes and passing a second elongated member through the other one of the pair of holes; tacking a first end of the first elongated member and a first end of the second elongated member to the panel; wherein each of the sidewalls of the pair of holes imposes a compressive force on an intermediate portion of one of the first and second elongated members; wherein each of the elongated members defines an earloop of adjustable length between its first end and the one of the pair of holes through which it passes.
 34. The method of claim 33, further comprising forming at least one pleat in the panel.
 35. The method of claim 33, further comprising tacking a second end of the first elongated member and a second end of the second elongated member to the panel to form a pair of take-up loops.
 36. The method of claim 33, wherein the fabric is one or more of a melt blown fabric, a resin-based fabric, and polymer-resin fabric.
 37. The method of claim 33, wherein the elongated members are elastically deformable.
 38. The method of claim 33, wherein the panel has a thickness no greater than 5 millimeters.
 39. The method of claim 33, wherein the panel is rectangular.
 40. A face mask comprising: a panel defined by at least one layer of fabric; the panel having a bonded portion; a pair of earloops attached to the panel; and means for adjusting the size of the earloops. 